Display stand for shipping and displaying consumer goods

ABSTRACT

A display stand for shipping and displaying goods is disclosed. The display stand preferably eliminates the need for separate inner boxes in a shipping container, resulting in less waste and less time being spent stocking shelves with products.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. provisional application Ser. No. 60/851,161 filed on Oct. 11, 2006, entitled “A DISPLAY STAND FOR SHIPPING AND DISPLAYING CONSUMER GOODS”, which is herein incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to product packaging. More particularly, this invention relates to efficiently packaging products in a form to be displayed on display shelves.

2. Description of the Related Art

Consumer products are typically shipped in an external container, e.g., a corrugated cardboard box, that encloses multiple inner boxes, e.g., cardboard boxes, each of which contains individual packages containing one or more products to be sold as a unit to a consumer. In some instances, the external container is opened at a distribution center and the inner boxes are sent to one or more retail stores. In other instances, the entire external container is sent to the retail store. Once at the retail location, the inner boxes are opened. In some instances, the individual packages of consumer goods are taken out of the inner boxes and then put on display shelves, e.g., hung on a display peg that is an integral part of a display wall or shelf where they can be purchased by consumers. In this instance, the inner-boxes are not used in the display of the individual product packages, and are disposed of once the product packages have been removed. In other instances, the inner boxes are partially disassembled and a portion of the inner box is used to hold the products when the partial inner box is put on a display shelf. In this instance, only a portion of the inner box is disposed of at the time the products are placed on the shelf, and the remainder is disposed of when the display portion is emptied of the product. However, the entire inner box still contributes to waste that must be disposed of by the retailer. In addition to the physical waste that these shipping containers create, the amount of time for a store clerk to unpack the external container and the inner boxes wastes time that could be used for other money making things (e.g., customer service). Even when the inner boxes are used to display the goods, typically only a portion of the inner box is used, requiring the person stocking the shelf to remove most of the inner box, requiring time and generating waste. What is needed is a method of packaging consumer goods that reduces the amount of waste and reduces the amount of time to unpack and display the individual product packages.

SUMMARY OF THE INVENTION

An embodiment provides a method of providing efficient packaging of products, for example, consumer goods, whereby waste materials associated with unpacking are reduced and time associated with displaying the consumer goods at a place of retail is reduced. The method comprises providing a plurality of product packages, providing one or more display stands, preferably peg stands configured with one or more pegs to support one or more of the plurality of the packages, the display stands being further configured such that an integer number of the display stands fit securely into a shipping container while supporting the consumer products, and loading the integer number of display stands holding the consumer products into the shipping container in preparation for shipping.

Another embodiment provides a kit for providing efficient packaging of consumer goods, whereby waste materials associated with unpacking are reduced and time associated with displaying the consumer goods at a place of retail is reduced. The kit comprises a plurality of consumer product packages, a shipping container, and one or more display stands, preferably peg stands configured with one or more pegs to support one or more of the plurality of packages, the display stands being further configured such that an integer number of the display stands fit securely into the shipping container while supporting the consumer products.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows an embodiment of a display stand for displaying consumer goods.

FIG. 1B shows another embodiment of a display stand for displaying consumer goods.

FIG. 1C shows another embodiment of a display stand for displaying consumer goods.

FIG. 1D shows another embodiment of a display stand for displaying consumer goods.

FIG. 2 shows a container for packaging the display stands shown in FIGS. 1A, 1B, 1C and 1D.

FIG. 3 shows another container for packaging the display stands shown in FIGS. 1A, 1B, 1C and 1D.

DETAILED DESCRIPTION OF CERTAIN INVENTIVE EMBODIMENTS

A method and apparatus for providing efficient packaging, unpacking and display of products is provided. An embodiment includes a display stand and multiple individual product packages, wherein a single container houses both the display stand and the individual product packages, preferably eliminating the need for inner boxes. The individual product packages, in some aspects, can be pre-installed onto the display stand. In a preferred embodiment, the display stands are peg stands configured with one or more pegs to support the product packages. The container housing the display stand and the individual product packages can be a shipping container, e.g., a corrugated cardboard box. By enabling a person to unpack the display stand and the individual packages at the same time, store shelves can be stocked in a more efficient manner. In addition, the lack of inner boxes, in some aspects, reduces the waste associated with the unpacking process. Other advantages and benefits will be apparent to those of skill in the art.

FIG. 1A shows an embodiment of a display stand for shipping and displaying products, typically consumer products. The display stand 100 includes a peg 105 that is used to support individual packages of a consumer product. The peg 105 preferably extends in a generally horizontal direction. The individual packages can include a hole or other hanging means that can slide over an end 110 of the peg 105. For example, the hanging means can comprise a substantially circular cutout portion offset from a slot in the top of the package wherein the peg can be slid through the slot to the circular cutout portion to support the package. In another embodiment, the hanging means of the individual packages is a hook that hooks over the peg 105. The cross sectional dimensions of the peg 105 can be sized to allow the hooks and/or holes of the individual packages to fit around the peg 105. The cross section can be round, square, oval, diamond, triangular or any other shape, The packages preferably hang in a generally vertical orientation.

The display stand 100 also includes one or more vertical members 115 connecting the peg 105 to a base portion including one or more cross members 120 and a center member 125. The cross members 120 provide lateral stability allowing the display stand to be free standing and resist tipping over in a direction generally perpendicular to the peg 105. The center member 125 provides longitudinal stability preventing the display stand 100 from tipping forward as a result of the weight of the individual packages being positioned near the end 110 of the peg 105. The center member 125 can advantageously be generally parallel to the peg 105. In one embodiment, the peg 105 is longer than the vertical member 115.

The vertical member 115 is sized to allow the individual packages to hang from the peg 105 without contacting, or significantly contacting, the center member 125. The center member 125 can be sized to fit onto store shelves. The center member 125 and the peg 105 preferably extend in the same direction, generally orthogonal to and separated by the vertical member 115.

The display stand 100 can also include a posting sign 130 that can be used, for example, to display product and/or price information. The example posting sign 130 is shown at a back end of the peg 105. However, the posting sign 130 can also be positioned at the front of the center member 125 or near the end 110 of the peg 105. It should be noted that positioning the posting sign 130 at the end 110 of the peg 105 can interfere with sliding packages onto the peg 105. In this configuration packages can be attached to the peg 105 with hooks. The individual packages can also include a hole formed in a tab connected to the package or a part of the package. The tab can include a slit that allows the package to be forced over the peg 105 without sliding the hole over the end 110.

FIG. 2 shows a container 150 for packaging the display stands shown in FIG. 1A. The container 150 is a shipping container for shipping one or more of the display stands 100 shown in FIG. 1A. Each display stand is pre-loaded, in this example, with individual product packages 155. The example shown contains three display stands 100. In some embodiments, the container 150 can contain multiple layers of display stands 100. In these embodiments, there can be a structural separation layer (not shown) between the stacked layers of display stands 100. The structural separation layer can comprise a piece of material (e.g., a recyclable material such as cardboard, preferably a biodegradable material). The structural separation layer should be configured to rest on the peg members 105 of the display stands 100 to provide additional support. In embodiments where the individual packages 155 are hanging on the peg members 105, the structural support layer can gain additional structural support by resting on the individual packages.

The example container 150 also includes a top 160 that fits over the top of or otherwise closes the container 150, thereby enclosing the display stands 100 and individual packages 155. Other forms of container tops (e.g., multiple flaps attached to the top edges of the container 150) known to those of skill in the art can also be used. While the example container 150 of FIG. 2 is shown containing the display stands 100 as shown in FIG. 1A, other display stands, such as those discussed in reference to FIGS. 1B, 1C and 1D below, can readily be contained as well.

FIG. 1B shows another embodiment of a display stand for shipping and displaying goods. The display stand 200 of this embodiment includes two peg members 205 connected to two vertical members 215. In one aspect, the two peg members 205 can allow for twice as many individual packages to be hung by a single display stand 200. In another aspect, the individual products can include two hooks and/or holes to slide over the peg members 205. In another embodiment not shown, the two pegs are joined at the front to form a u-shaped loop, optionally with additional support members connecting the two pegs at other positions along their length. Alternatively, the loop can be a flat tongue-like structure that is solid or has one or more holes. The product packages can have a corresponding wide slot to slide over the front of the u-shaped loop or tongue-like structure. The additional hooks and/or holes or wide slot provide for additional structural integrity and stability of the individual products. This can be a benefit during shipping, for example. Whereas this example shows two vertical members 215, some embodiments (not shown) include just one vertical member attached at the top by a cross member to form a “T” which is then connected to the two peg members 205. In one embodiment, a peg member 205, a vertical member 215, and a center member 225 are all formed from a single continuous rod.

The display stand 200 also includes a base portion connected to the vertical members 215. The base portion includes cross members 220 connected to center two center members 225, where the cross members 220 and center members 225 provide stability preventing the display stand from tipping over during shipping and during display on a shelf. Each of the cross members 220 includes two pads 230. The pads 230 can prevent slippage on a shelf and/or prevent damage to a shelf (e.g., to a wooden shelf). The base portion and the peg members 205 are preferably generally parallel to each other and are preferably generally parallel and extend in the same direction from the vertical members 215.

The display stand 200 offers an advantage because the pair of peg members 205 can result in added stability when multiple display stands 200 are stacked within a shipping container such as the container 150 of FIG. 2.

FIG. 1C shows another embodiment of a display stand for shipping and displaying goods. Display stand 300 comprises a base panel 320 instead of the cross members and center members of the display stands 100 and 200 in FIGS. 1A and 1B respectively. The base panel 320 is attached to a vertical member 315 which is attached to a peg member 305. In this embodiment, the display stand 300 can be formed of a single piece (e.g., molded plastic, preferably comprising biodegradable material). The base panel 320 offers an advantage when packaged in a shipping container, such as the container 150 of FIG. 2, since the panels 320 can be place side by side in close proximity in the container to prevent movement. In addition, the panels can provide sufficient stability when the display stands 300 are stacked on top of each other. This added stability can negate the need for the structural separation layer as discussed above. In one embodiment, the display stand 300 comprises an optional stability member 325 attached to the peg member 305. This stability member 325 provides stability to a second display stand 300 that is stacked on top of the first display stand 300 when loaded in a shipping container.

FIG. 1D shows another embodiment of a display stand for shipping and displaying consumer goods. Display stand 400 includes a base panel 420 that is similar to the base panel 320 in the display stand 300. However, the display stand 400 includes two vertical members 415 and two peg members 405. As discussed above in reference to FIG. 1B, in one aspect, the two peg members 405 can allow for twice as many individual packages to be hung by a single display stand 400. In another aspect, the individual products can include two hooks and/or holes to slide over the peg members 405. The additional hooks and/or holes provide for additional structural integrity and stability of the individual products. This can be a benefit during shipping, for example. The display stand 400 can also provide for added stability when positioned side-by-side or stacked as discussed above in reference to FIG. 1C.

The base panels 320 and 420 shown in FIGS. 1C and 1D, respectively, are depicted as being solid pieces. However, in some embodiments, the base panels can include struts and/or cut out portions configured such that the struts and/or remaining portions provide sufficient rigidity to support the products and provide stability both during shipping and on a display shelf. These embodiments can reduce the weight of the display stands and reduce the amount of waste to further improve the efficiency of the packaging system.

The base panels 320 and 420, in FIGS. 2 and 3, are preferably rectangular such that when placed side by side, they provide stability and prevent twisting of the display stands within the shipping containers. However, those skilled in the art will recognize that base panels comprising other shapes (e.g., triangular, square, hexagonal, circular, elliptical, etc.) may also be used.

The display stands 100, 200, 300 and 400 can be formed of any suitable material including plastics or other polymers, metals, paper, cardboard, biodegradable plastics or polymers, wood etc. The material and amount of material in each member should be chosen to provide sufficient structural integrity to support the displayed products and to take the impacts that can be experienced during shipping. The materials can be recyclable, but are preferably biodegradable. Several biodegradable materials are discussed in the paper “Biodegradable Polymers: A Rebirth of Plastic,” written by Shellie Berkesch, and published online by the Institute of Packaging Professionals. Biodegradable materials include soy based plastics which are discussed in “Biofibres, Biodegradable polymers and Biocomposites”, by A. K. Mohantya, b, M. Misraa, b, G. Hinrichsen, Technical University of Berlin, Institute of Nonmetallic Materials, Polymer Physics, Englische STR. 20, D-10587 Berlin, Germany (Sep. 27, 1999, revised Mar. 2, 2000); or as discussed by E. S. Stevens at the Greenplastics website. The above references are herein incorporated by reference.

The display devices 100, 200, 300 and 400 can be manufactured as a single piece (e.g., molded plastic) or in separate pieces that are connected by techniques known in the art. Individual pieces can be connected by adhesives, glues, fasteners, welds, bonding, etc.

An embodiment of a method for delivering products with the display stands discussed above will now be discussed. The individual packages are configured to be displayed by hanging on one of the display stands 100, 200, 300 and 400 discussed above. In one aspect the individual packages are pre-hung on the display stand. One or more display stands 100 containing pre-hung individual packages 155 are then loaded into a container such as the container 150 in FIG. 2. In one embodiment, multiple display stands are loaded into the container, arranged in one or more vertical stacks, and horizontal rows. The container is then shipped to a place where the products are displayed, typically a retail store, department store, or warehouse store. After being shipped and unloaded from a shipping vehicle, at the place of display and/or sale, the container is opened and the display stands, including the pre-hung individual product packages, are then removed from the container and put directly on display shelves, tables or other platform large enough to hold the display stand. Thus the retail shelves can be stocked very quickly and there is very little wasted packing material. The display stands can be recycled or left to bio-degrade, when the retail product has been removed and sold. Thus time is saved and material waste is reduced. In some embodiments the shipping container is opened at a distribution center and the display stands, including the pre-hung individual product packages, are shipped to several places of display and/or sale.

FIG. 3 shows another container for packaging the display stands shown in FIGS. 1A, 1B, 1C and 1D. A container 500 is configured to securely enclose two display stands. For the sake of clarity, the container 500 is depicted as being transparent such that the display stands inside can be viewed. A first display stand 505 (e.g. similar in configuration to the display stand 400 shown in FIG. 1D) sits on the bottom of the container 500 and a second display stand 510 sits on top of the first display stand 505. For the sake of clarity, the display stands 505 and 510 are not shown holding any products, however, in one embodiment, the display stands 505 and 510 can both be fully loaded with products ready to be displayed on a shelf. In this example, the first display stand 505 has two straight horizontal members 506 configured such that the flat base panel of the display stand 510 sits flat and stably upon the horizontal members 506. In another embodiment, not shown, the base panel of the second display stand 510 could have a cutout portion to accommodate a curved horizontal member such as shown in the second display stand 510 and the display stands shown in FIGS. 1A-1D. In addition, the base panel of the second display stand 510 could also include grooves on the bottom surface such that the horizontal members 506 fit into the grooves and provide additional stability. In one embodiment, the base panel of the display stand 510 can include grooves and/or cutout portions configured to allow portions of the packages that extend above the horizontal members 506 of the lower display stand 505 to fit into the grooves and/or cutout portions and provide additional stability.

The two horizontal members 506 provide stability such that the second display stand 510 does not tip to one side or the other. In another embodiment, display stands with a single horizontal member (such as the display stand 300 shown in FIG. 1C) can be stacked and stability can be provided by the products hanging on the horizontal members. For example, the products can comprise a semi rigid cardboard tab with a hole that slides over the horizontal member. When the display stand is substantially fully loaded with such products, the semi-rigid tabs can support the second display stand stacked on top of the first display stand.

The container 500 also includes a top 515 that fits over the top of the container 500, thereby enclosing the display stands 510 and 515 and individual packages (not shown). Other forms of container tops (e.g., multiple flaps attached to the top edges of the container 200) known to those of skill in the art can also be used.

The shipping containers discussed above illustrated a single row of 3 display stands in FIG. 2, and two display stands stacked in two layers in FIG. 3. However, depending on the size of the products and the size of the display stands, other configurations of rows, columns and layers (where a layer can include multiple rows and/or columns) of display stands may be used. For example, the display stands may be contained in a shipping container where the number of rows and or columns of display stands range from about 1 to about 20, preferably from about 1 to about 5 rows and/or columns of display stands on a single layer. Those skilled in the art will recognized that 1 to 20 rows and/or columns includes embodiments with 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20 rows and/or columns, or a range defined by any two of these values. In addition, the shipping container may include multiple layers of stacked display stands including from about 1 to about 20 layers of stacked display stands, preferably from about 1 to about 5 stacked layers. Those skilled in the art will recognized that 1 to 20 stacked layers includes embodiments with 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20 stacked layers, or a range defined by any two of these values.

In one embodiment, the individual display stands 100, 200, 300 and/or 400, and the products which they support, are enclosed in enveloping means prior to being loaded in the containers 150 or 500. The enveloping means can include any type of wrapping material, preferably a shrink wrap and more preferably a biodegradable shrink wrap, or any other enveloping means. The enveloping means serves to secure the product from moving around during shipping and possibly falling off the peg member of the display stand, particularly in the embodiment where the shipping container is opened at a distribution center and individual stands are shipped to retail stores or other places of display/sale. The enveloping means can also serve to provide strength and stability to the display stands that are arranged in rows and/or stacked in the shipping containers, such as those illustrated in FIGS. 2 and 3. The enveloping means can be clear or opaque. The enveloping means can also be labeled with product identifying means such as a bar code or text describing the number and type of product that is contained within.

The dimensions of display stands illustrated in FIGS. 1A, 1B, 1C and 1D can be of dimensions sized to accommodate various sized products. For example, small products such as razors, makeup (e.g., lipstick, mascara, etc.), watches, etc. ranging in size from about 1, 2, 3, 4 to 5 inches in height, width and/or depth may be accommodated by display stands sized to efficiently hold the products without wasting shelf space. Larger products, such as car parts, cookware, and others ranging in size from about 6, 8, 10, 15, 20 or more inches in height width and/or depth may also be accommodated by embodiments of the display stands illustrated in FIGS. 1A-1D.

Waste material associated with packaged products typically comprises two types. A first type of packaging waste is the waste associated with the packaging that holds the product, which in a retail setting is taken home by the consumer after purchasing the product (“consumer waste”). A second type of packaging waste is the waste that remains at the place of display/sale, typically a retail store (“retailer waste”). The embodiments of methods and systems for containing, shipping and displaying products described herein preferably reduce the amount of this second type of waste material, the “retailer waste.” Embodiments of the packaging methods and systems described above can result in the amount of packaging waste remaining at the place of display/sale (“retailer waste”) being reduced by an amount that is, is about, is at least, is at least about, 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50% less than the amount of standard packaging comprising a cardboard inner box. The comparison can be made by measuring the amount of “retailer waste” generated to ship and display a given number of product packages using an embodiment of the instant invention, and dividing that amount by the amount of “retailer waste” generated to ship and display the same number of product packages using standard cardboard inner boxes. These values of “retailer” packaging waste reduction can be measured in terms of volume or weight. A reduction in the volume of waste can reduce the costs associated with storing the waste before it is picked up by recyclers and/or waste management services. A reduction in the overall weight of the packaging waste can result in a reduction of the cost involved in disposing of the packaging waste, as well as shipping the product. In the retail setting where hundreds of products are shipped and unpacked every day, even small reductions in waste can be significant when considering all the stores in a retail chain, or when considering a single stores waste over a given period of time.

While the invention and embodiments disclosed herein are often discussed in terms of consumer goods, retail stores, and consumers, one of skill in the art will recognize that the invention is not so limited. The place of unpacking the inner box can be any location that receives the goods to be displayed and/or sold, and is not limited to retail stores. Examples of locations other than retail stores which must contend with packaging waste and time associated with unpacking include, for example, office supply rooms, hospital supply rooms, and individual's homes when products are purchased in bulk. Thus, “consumers” include, for example, workers in the office, hospital staff, or people living in the home, that remove the individual product package from the display for use. Therefore, “consumer,” “retailer,” “consumer waste,” “retailer waste,” etc. as used herein are descriptive terms that are not intended to limit the scope of the invention to the retail store setting where product packages are purchased by a consumer and taken from the store.

Therefore, it is understood that the foregoing description details certain embodiments of the invention. It will be appreciated, however, that no matter how detailed the foregoing appears in text, the invention can be practiced in many ways. It should be noted that the use of particular terminology when describing certain features or aspects of the invention should not be taken to imply that the terminology is being redefined herein to be restricted to including any specific characteristics of the features or aspects of the invention with which that terminology is associated. The scope of the invention should therefore be construed in accordance with the appended claims and any equivalents thereof. 

1. A method of providing efficient packaging of products for display or sale, whereby waste materials associated with unpacking are reduced and time associated with displaying the products at a place of display or sale is reduced, the method comprising: providing a plurality of product packages; providing one or more display stands, each display stand configured to support one or more of the plurality of the product packages, the display stands being further configured such that an integer number of the display stands fit securely into a shipping container while supporting the consumer products; and loading the integer number of display stands holding the product packages into the shipping container in preparation for shipping.
 2. The method of claim 1, wherein the display stands each comprise one or more support pegs configured to support the product packages and the product packages each comprise one or more hanging means configured to fit over the one or more pegs of the display stand, the method further comprising attaching the product packages to the one or more pegs via hanging means prior to loading the display stands into the shipping container.
 3. The method of claim 2, wherein the hanging means comprises a hook.
 4. The method of claim 2, wherein each of the display stands comprises a base member configured to support the one or more support pegs and to provide stability.
 5. The method of claim 4, wherein the base member comprises a substantially flat panel.
 6. The method of claim 1, wherein loading the integer number of display stands holding the products packages into the shipping container comprises stacking one of the display stands on top of another one of the display stands.
 7. The method of claim 6, wherein there is no additional structural support material between the stacked display stands.
 8. The method of claim 1, wherein the display stand is at least partially formed of one or more biodegradable materials.
 9. The method of claim 8, wherein the biodegradable materials comprise a soy-based plastic.
 10. The method of claim 1, wherein the retailer waste is reduced by about 5% by weight compared to standard packaging comprising a corrugated cardboard external container enclosing cardboard inner boxes.
 11. The method of claim 1, further comprising surrounding at least one of the display stands and the supported packages using an enveloping means prior to loading.
 12. The method of claim 11, wherein the enveloping means comprises shrink wrap.
 13. A kit for providing efficient packaging of product packages, whereby waste materials associated with unpacking are reduced and time associated with displaying the product packages at a place of display or sale is reduced, the kit comprising: a plurality of product packages; a shipping container; and one or more display stands, each display stand configured to support one or more of the plurality of packages, the display stands being further configured such that an integer number of the display stands fit securely into the shipping container while supporting the product packages.
 14. The kit of claim 13, wherein the display stands each comprise one or more support pegs configured to support the product packages and the product packages each comprise one or more hanging means configured to fit over the one or more pegs of the display stand.
 15. The kit of claim 14, wherein the hanging means comprises a hook.
 16. The kit of claim 14, wherein each of the display stands comprises a base member configured to support the one or more support pegs and to provide stability.
 17. The kit of claim 16, wherein the base member comprises a substantially flat panel.
 18. The kit of claim 13, wherein the display stand is at least partially formed of one or more biodegradable materials.
 19. The kit of claim 18, wherein the biodegradable materials comprise a soy-based plastic.
 20. The kit of claim 13, wherein the retailer waste is reduced by about 5% by weight compared to standard packaging comprising a corrugated cardboard external container enclosing cardboard inner boxes.
 21. The kit of claim 13, further comprising enveloping means configured to surround at least one of the display stands and the one or more supported product packages.
 22. The kit of claim 21, wherein the enveloping means comprises shrink wrap. 